US20080018193A1 - Terminal for Rotating Armature - Google Patents
Terminal for Rotating Armature Download PDFInfo
- Publication number
- US20080018193A1 US20080018193A1 US11/685,743 US68574307A US2008018193A1 US 20080018193 A1 US20080018193 A1 US 20080018193A1 US 68574307 A US68574307 A US 68574307A US 2008018193 A1 US2008018193 A1 US 2008018193A1
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- US
- United States
- Prior art keywords
- terminal
- plate
- shaped piece
- leading end
- coupler
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
- H02K5/225—Terminal boxes or connection arrangements
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
Definitions
- the present invention relates to a terminal for a rotating armature.
- a stator is stored in a housing, resin bobbins are attached to a plurality of cores constituting the stator, respective U-phase, V-phase and W-phase coils are wound around a coil winding portion of the bobbins.
- a resin portion of a terminal is integrally formed by resin molding respective ring main bodies of three bus rings A to C and a neutral bus ring D that are attached to the resin bobbin of the stator.
- bus rings A to C of the terminal are respectively connected to the U-phase, V-phase and W-phase coil terminals of the stator
- the neutral bus ring D is connected to common terminals of the respective coils
- the coils are star connected
- respective U-phase, V-phase and W-phase connection terminals of a coupler are attached to a housing connected to a connection portion connected to the ring main bodies of the bus rings A to C of the terminal and protruding from the resin portion.
- the connection between the respective connection terminal of the coupler and the connection portion of the respective bus rings may be achieved by a welding in addition to a bolt fastening.
- FIG. 13A shows a bus ring A in accordance with a conventional structure
- FIG. 13B shows a terminal 1 .
- the terminal 1 is structured such that ring main bodies 2 of the respective bus rings A to D are arranged in parallel in an axial direction thereof so as to be resin molded to a resin portion 1 A.
- a terminal portion 3 to which a coil terminal of each of the motor coils is connected is protruded to an outer side in a radial direction from an outer periphery of the resin portion 1 A.
- a connection portion 4 welded to each of the connection terminals of the coupler is protruded to an outer side in an axial direction from a side portion of the resin portion LA.
- each of the bus rings A to C has an L-shaped plate-like piece 2 A formed by including the ring main body 2 as a plate shape included in a plane orthogonal to an axial direction thereof, bending in an axial direction from a part of an inner periphery of the ring main body 2 and bent to an outer side in a radial direction, the L-shaped plate-like piece 2 A is protruded from the resin portion 1 A, and a leading end side portion of the L-shaped plate-like piece 2 A is formed as the weld connection portion 4 .
- An object of the present invention is to improve a bending formability of a connection terminal of a bus ring, and to improve an insert mold formability of the bus ring, in a terminal for a rotating armature.
- the present invention relates to a terminal for a rotating armature.
- Ring main bodies of bus rings (A-C) respectively are connected to U-phase, V-phase and W-phase coils of a stator, and a neutral bus ring (D) connected to common terminals of the respective coils, are arranged in parallel in an axial direction thereof to be resin molded in a resin portion.
- Each of the bus rings (A-C) formed as a plate shape in which a ring main body of each bus ring is included in a plane orthogonal to the axial direction.
- a plate-shaped piece is bent in a direction along the axial direction from one end in a peripheral direction of each of the ring main bodies.
- the plate-shaped piece of each of the bus rings (A-C) is protruding from the resin portion.
- a leading end side portion of the plate-shaped piece is formed as a connection portion to each of the connection terminals of the coupler.
- FIG. 1 is a cross sectional view showing a motor
- FIGS. 2A and 2B show a stator assembly, iii which FIG. 2A is a cross sectional view and FIG. 2B is an enlarged view of a main portion;
- FIGS. 3A and 3B show the stator assembly, in which FIG. 3A is a front elevational view and FIG. 3B is an enlarged view of the main portion;
- FIG. 4A and 4B show a sub assembly in which a terminal is attached to a stator, in which FIG. 4A is a cross sectional view and FIG. 4B is an enlarged view of a main portion;
- FIGS. 5A and 5B show a core sub assembly, in which FIG. 5A is a cross sectional view along a line A-A in FIG. 5B , and FIG. 5B is an end elevational view.
- FIGS. 6A to 6D show a terminal, in which FIG. 6A is a cross sectional view, FIG. 6B is a front elevational view, FIG. 6C is an enlarged view of a main portion of FIG. 6A , and FIG. 6D is an enlarged view of a main portion of FIG. 6B ;
- FIGS. 7A to 7C show a bus ring A, in which FIG. 7A is a front elevational view, FIG. 7B is a cross sectional view along a line B-B in FIG. 7A , and FIG. 7C is a plan view;
- FIGS. 8A to 8C show a bus ring B, in which FIG. 8A is a front elevational view, FIG. 8B is a cross sectional view along a line B-B in FIG. 8A , and FIG. 8C is a plan view;
- FIGS. 9A and 9B show a bus ring C, in which FIG. 9A is a front elevational view, and FIG. 9B is a cross sectional view along a line B-B in FIG. 9A ;
- FIGS. 10A and 10B show a bus ring D, in which FIG. 10A is a front elevational view, and FIG. 10B is a cross sectional view along a line B-B in FIG. 10A ;
- FIGS. 11A and 11B show a coupler, in which FIG. 11A is a cross sectional view and FIG. 11B is a front elevational view;
- FIGS. 12A and 12B show a metal mold dividing direction of the bus ring and the terminal in accordance with the present invention, in which FIG. 12A is a perspective view and FIG. 12B is a side elevational view; and
- FIGS. 13A and 13B show a metal mold dividing direction of the bus ring and the terminal in accordance with the prior art, in which FIG. 13A is a perspective view and FIG. 13B is a side elevational view.
- a DC brushless motor 10 corresponding to a rotating armature in accordance with the present invention is structured, as shown in FIG. 1 , such that an end housing 12 is attached to one end of a stator assembly 11 , and a rotor assembly 13 is rotatably supported to the stator assembly 11 and an inner portion of the end housing 12 .
- the stator assembly 11 is structured, as shown in FIGS. 2A to 3B , such that a sub assembly of a cylindrical stator 20 and a terminal 30 is stored in an inner periphery of a yoke integrally formed with the housing 11 A and a coupler 40 attached to the housing 11 A is connected to the terminal 30 .
- the stator 20 is structured, as shown in FIGS. 4A and 4B , such that a plurality of, for example, four in each of U-phase, V-phase and W-phase (totally twelve) core sub assemblies 20 A in the present embodiment, fitted to the inner periphery of the housing 11 A are arranged adjacently on a circumference.
- the core sub assembly 20 A is structured by laminating a plurality of cores 21 constituted by silicon steel plates, attaching a resin bobbin 22 to the laminated core 21 and winding respective motor coils 23 forming three phases constituted by the U-phase, the V-phase and the W-phase around a coil winding portion 22 A of the resin bobbin 22 , as shown in FIGS. 5A and 5B .
- Each of the motor coils 23 is structured such that both ends constituted by a wind starting end and a wind terminating end are respectively set to a coil terminal 23 A and a common terminal 23 B, and these terminals 23 A and 23 B are extended to an outer side from one end side of the coil winding portion 22 A of the resin bobbin 22 .
- the resin bobbin 22 is provided with a terminal mounting portion 22 B (a concave portion) protruding in an axial direction of the housing 11 A along an inner periphery of the housing 11 A, in one end side of the coil winding portion 22 A ( FIG. 2B ).
- the terminal 30 is attached to the resin bobbin 22 so as to be positioned in a peripheral direction, an axial direction and a diametrical direction by being embedded in a resin portion 31 formed by the resin mold so as to be integrated, in a state in which respective ring main bodies 32 of three bus rings A to C and the neutral bus ring D are arranged in parallel in an axial direction, and locking mounting hooks 31 A provided at a plurality of positions in an outer periphery of the resin portion 31 to a concave portion of the terminal mounting portion 22 B of the resin bobbin 22 , as shown in FIGS. 6A to 6D .
- the ring main bodies 32 of the bus rings A to C are formed in a C-shaped form so as to be partly cut in the peripheral direction, and the ring main body 32 of the neutral bus ring D is formed in an annular shape continuously formed in the peripheral direction.
- Each of the bus rings A to D is connected to the ring main body 32 thereof so as to extend to an outer side in the radial direction of the ring main body 32 , and is provided with a terminal portion 33 protruding to an outer portion of the resin portion 31 , as shown in FIGS. 7A to 10B .
- the bus ring A is provided with four terminal portions 33 to which the coil terminals 23 A of four U-phase motor coils 23 are connected, in the present embodiment.
- the bus ring B is provided with four terminal portions 33 to which the coil terminals 23 A of four V-phase motor coils 23 are connected, in the present embodiment.
- the bus ring C is provided with four terminal portions 33 to which the coil terminals 23 A of four W-phase motor coils 23 are connected, in the present embodiment.
- the neutral bus ring D is provided with twelve terminal portions 33 to which the common terminals 23 B of twelve motor coils 23 are connected, in the present embodiment. Accordingly, each of the motor coils 23 is star connected by connecting each of the terminal portions 33 connected to the ring main body 32 of each of the bus rings A to C of the terminal 30 and protruding to an outer side in a radial direction from an outer periphery of the resin portion 31 to the coil terminal 23 A of each of the U-phase, V-phase and W-phase motor coils 23 of the stator 20 , and connecting the terminal portion 33 connected to the ring main body 32 of the neutral bus ring D and protruding from the resin portion 31 to the common terminal 23 B of each of the motor coils 23 .
- the terminal portion 33 is provided with a leading end concave portion 33 B pinched by a leading end hook portion 33 A so as to form a U-shaped outline as shown in FIG. 6D .
- the terminals 23 A and 23 B of each of the motor coils 23 are assembled in such a manner as to be fitted to the leading end concave portion 33 B of the terminal portion 33 of the corresponding bus ring A to D, and are caulked between the leading end hook portions 33 A of the terminal portion 33 so as to be welded to the terminal portion 33 .
- Each of the bus rings A to C is provided with an external portion connecting connection portion 34 connected to the ring main body 32 so as to be bent and stand in a direction along the axial direction of the ring main body 32 from one end in the peripheral direction of the ring main body 32 , and protruding to an outer side in an axial direction from the side portion of the resin portion 31 , as shown in FIGS. 7A to 9B .
- connection portions 34 of the bus rings A to C are arranged in parallel to each other ( FIG. 6B ).
- the coupler 40 is structured, as shown in FIGS. 11A and 11B , such that U-phase, V-phase and W-phase connection terminals 42 connected to a control circuit in an external portion are embedded in a resin body 41 screwed into the outer surface of the housing 11 A.
- Each of the U-phase, V-phase and W-phase connection terminals 42 of the coupler 40 is inserted to an inner portion of the housing 11 A, and is connected to the connection portion 34 of each of the bus rings A to C of the terminal 30 .
- Each of the connection terminals 42 is inserted to each of the connection portions 34 so as to be mated, and welded, as mentioned below.
- the motor 10 has a resolver 50 , as shown in FIG. 1 , constituted by a resolver rotor portion 51 and a resolver stator portion 52 .
- the resolver rotor portion 51 rotating together with the rotating shaft 13 A is attached to an outer periphery of the rotating shaft 10 A of the rotor assembly 13 .
- the resolver stator portion 52 is attached to a side of the stator 20 , that is, an inner periphery of the end housing 12 .
- the resolver stator 52 is arranged in such a manner as to surround the resolver rotor portion 51 , and detects a rotational position of the rotating shaft 13 A on the basis of a change of a reluctance generated with respect to the resolver rotor portion 51 caused by the rotation.
- a predetermined pattern of current is supplied to each of the U-phase, V-phase and W-phase motor coils 23 of the stator 20 via the coupler 40 and the terminal 30 by the external control circuit in correspondence to the detected rotational position of the rotating shaft 15 A, and the drive of the motor 10 is controlled.
- the motor 10 has the following structures.
- each of the bus rings A to C is structured, as shown in FIGS. 12A and 12B ( FIG. 12A shows the bus ring A as a representative), such that each of the ring main bodies 32 is formed in a plate shape included in a plane orthogonal to an axial direction thereof (a direction along a center axis of a circular ring of each of the ring main bodies 32 ), and has a plate-shaped piece 35 bent in a straight shape in a direction along an axial direction from one end in a peripheral direction of each of the ring main bodies 32 .
- the plate-like piece 35 of each of the bus rings A to C is protruded toward all outer side in the axial direction from the resin portion 31 , and a leading end side portion of the plate-like piece 35 is formed as a connection portion 34 to each of the connection terminals 42 of the coupler 40 .
- reference symbol P denotes a dividing direction of the metal mold at a the of forming the resin portion 31 of the terminal 30 by insert molding the bus rings A to D.
- the plate-shaped piece 35 forming the connection portion 34 of the coupler 40 to each of the connection terminals 42 and protruding from the resin portion 31 in each of the bus rings A to C is bent in a direction along the axial direction from the ring main body 32 of each of the bus rings A to C.
- the plate-shaped piece 35 forming the connection portion 34 of the bus rings A to C extends in parallel in the dividing direction P thereof at a time of insert molding, by inserting each of the bus rings A to D into the metal mold so as to form the resin portion 31 , and intending to divide the metal mold along the axial direction, it is not necessary to arrange the slide metal mold orthogonal to the dividing direction P, and the insert molding formability of the bus rings A to D is good.
- the motor 10 has the following structures.
- each of the bus rings A to C is provided with a heat radiation portion 36 positioned in an outer side of the resin portion 31 so as to be exposed, between the ring main body 32 molded to the resin portion 31 and the connection portion 34 , as shown in FIGS. 2A to 4B .
- each of the bus rings A to C has a plate-shaped piece 35 formed by the ring main body 32 in a C-shaped form, bent in a direction along the axial direction of the ring main body 32 from one end in the peripheral direction of each of the ring main bodies 32 so as to stand up, and protruding toward an outer side in the axial direction from the resin portion 31 .
- a root side portion with respect to the resin portion 31 of the plate-shaped piece 35 in the plate-shaped piece 35 of each of the bus rings A to C is formed as the heat radiation portion 36 extending in a radial direction of the ring main body 32 so as to be formed long.
- a leading end side portion of the plate-shaped piece 35 a small piece portion in a leading end lower side protruding from a center side end in the radial direction of the ring main body 32 in the plate-shaped piece 35 toward the outer side in the axial direction of the ring main body 32 is formed as a weld connection portion 134 .
- the terminal 30 is provided with a positioning portion 37 mentioned below for the connection terminal 42 of the coupler 40 , in a leading end upper side of the plate-shaped piece 35 .
- each of the connection terminals 42 of the coupler 40 is mated with the connection portion 34 protruding to the outer side in the axial direction from the resin portion 31 via the heat radiation portion 36 , in each of the bus rings A to C of the terminal 30 , and is welded, as shown in FIGS. 2A to 3B .
- Each of the bus rings A to C of the terminal 30 is provided with the heat radiation portion 36 positioned in the outer side of the resin portion 31 , between the ring main body 32 and the connection portion 34 . Accordingly, the heat generated at a time of welding each of the connection terminals 42 of the coupler 40 to the connection portion 34 of each of the bus rings A to C is air cooled and radiated by the heat radiation portion 36 positioned in the outer side of the resin portion 31 , before being transmitted to the ring main body 32 , and is not directly accumulated in the resin portion 31 , whereby it is possible to easily prevent the resin portion 31 from melting and being dispersed.
- Each of the bus rings A to C of the terminal 30 has the plate-shaped piece 35 connected to the ring main body 32 , and protruding in the axial direction from the resin portion 31 , the root portion with respect to the resin portion 31 of the plate-shaped piece 35 is formed as the heat radiation portion 36 , and the leading end side portion of the plate-shaped piece 35 is formed as the weld connection portion 34 . Accordingly, the heat radiation portion 36 positioned in the outer side of the resin portion 31 is set to a plate-shaped area having a great surface area, and it is possible to easily secure the required heat radiating performance.
- the motor 10 has the following structures.
- each of the bus rings A to C is provided with a positioning portion 37 positioning and guiding each of the connection terminals 42 of the coupler 40 to a predetermined connection position to the connection portion 34 , in the connection portion 34 thereof as shown in FIGS. 2A to 4B .
- each of the bus rings A to C has a plate-shaped piece 35 protruding in the axial direction and forming the connection portion 34 as mentioned above shown in FIGS.
- each of the connection terminals 42 of the coupler 40 is formed as a band-plate shaped plate-shaped piece 43 as shown in FIGS. 11A and 11B , and a slit 43 B having a fixed length is formed in a bifurcated leading end fork portion 43 A formed in a side of the leading end portion of the plate-shaped piece 43 .
- each of the connection terminals 42 is positioned in three mutually orthogonal directions comprising an axial direction, an axial perpendicular direction and a radial direction of the terminal 30 by fitting the slit 43 B of the leading end fork portion 43 A in each of the connection terminals 42 of the coupler 40 to a groove bottom portion of the positioning groove 37 A provided in the plate-shaped piece 35 in each of the bus rings A to C of the terminal 30 .
- each of the connection terminals 42 is precisely positioned to a predetermined connection position of the connection portion 34 of each of the bus rings A to C.
- the leading end fork portion 43 A of the plate-shaped piece 43 in each of the connection terminals 42 of the coupler 40 forms the air gap portion 38 (serving as the air cooling heat radiation portion of the connection portion 34 to which the leading end fork portion 43 A of the connection terminal 42 is welded) among the plate-shaped portion 35 of the positioning portion 37 in each of the bus rings A to C, the positioning portion 37 and the connection portion 34 , as shown in FIGS. 2A to 3B , and further pinches the plate-shaped piece 35 of the connection portion 34 , and the leading end fork portion 43 A of the plate-shaped piece 43 in each of the connection terminals 42 is welded to the plate-shaped piece 35 of the connection portion 34 in each of the bus rings A to C.
- the positioning portion 37 provided in the connection portion 34 of each of the bus rings A to C positions and guides each of the connection terminals 42 of the coupler 40 to the predetermined connection position between the connection portions 34 of each of the bus rings A to C. Accordingly, it is possible to easily mate the weld portion between each of the connection terminals 42 of the coupler 40 and each of the bus rings to the connection position thereof so as to intend to stabilize the welding between the both, and it is possible to improve an assembling workability and a welding characteristic between the both.
- connection terminal 42 of the coupler 40 is derived and guided to the positioning groove 37 A provided in the connection portion 34 of each of the bus rings A to C so as to be smoothly positioned at the connection position to the connection portion 34 .
Abstract
In a terminal for a rotating armature, each of bus rings (A-C) is structured such that each of ring main bodies is formed as a plate shape included in a plane orthogonal to an axial direction thereof and has a plate-shaped piece folded in a direction along the axial direction from one end in a peripheral direction of each of the ring main bodies, the plate-shaped piece of each of the bus rings (A-C) protrudes from a resin portion, and a leading end side portion of the plate-shaped piece is formed as a weld connection portion to each of connection terminals of a coupler.
Description
- 1. Field of the Invention
- The present invention relates to a terminal for a rotating armature.
- 2. Description of the Related Art
- In a conventional rotating armature, as described in Japanese patent Application Laid-open No. 2001-25187 (patent document 1), a stator is stored in a housing, resin bobbins are attached to a plurality of cores constituting the stator, respective U-phase, V-phase and W-phase coils are wound around a coil winding portion of the bobbins. A resin portion of a terminal is integrally formed by resin molding respective ring main bodies of three bus rings A to C and a neutral bus ring D that are attached to the resin bobbin of the stator. Further, the bus rings A to C of the terminal are respectively connected to the U-phase, V-phase and W-phase coil terminals of the stator, the neutral bus ring D is connected to common terminals of the respective coils, the coils are star connected, and respective U-phase, V-phase and W-phase connection terminals of a coupler are attached to a housing connected to a connection portion connected to the ring main bodies of the bus rings A to C of the terminal and protruding from the resin portion. The connection between the respective connection terminal of the coupler and the connection portion of the respective bus rings may be achieved by a welding in addition to a bolt fastening.
-
FIG. 13A shows a bus ring A in accordance with a conventional structure, andFIG. 13B shows aterminal 1. Theterminal 1 is structured such that ringmain bodies 2 of the respective bus rings A to D are arranged in parallel in an axial direction thereof so as to be resin molded to aresin portion 1A. In each of the bus rings A to D, aterminal portion 3 to which a coil terminal of each of the motor coils is connected is protruded to an outer side in a radial direction from an outer periphery of theresin portion 1A. In each of the respective bus rings A to C, aconnection portion 4 welded to each of the connection terminals of the coupler is protruded to an outer side in an axial direction from a side portion of the resin portion LA. At this time, each of the bus rings A to C has an L-shaped plate-like piece 2A formed by including the ringmain body 2 as a plate shape included in a plane orthogonal to an axial direction thereof, bending in an axial direction from a part of an inner periphery of the ringmain body 2 and bent to an outer side in a radial direction, the L-shaped plate-like piece 2A is protruded from theresin portion 1A, and a leading end side portion of the L-shaped plate-like piece 2A is formed as theweld connection portion 4. - However, in the
terminal 1, since a bent portion in the leading end side of the L-shaped plate-like piece 2A in each of the bus rings A to C is bent to the outer side in the radial direction, a complicated bending procedure is necessary, and it is necessary to form anyslide metal mold 5 orthogonal to a dividing direction between the bent portion along the radial direction in the leading end side of the L-shaped plate-like piece 2A in the bus rings A to C and theresin portion 1A, at a time of arranging so as to insert the bus rings A to D within the metal mold, thereby insert molding, and intending to divide the metal mold along an axial direction P. Accordingly, an insert mold characteristic of the bus rings A to D is bad in addition to a bending formability of the connection terminal of the bus ring. - An object of the present invention is to improve a bending formability of a connection terminal of a bus ring, and to improve an insert mold formability of the bus ring, in a terminal for a rotating armature.
- The present invention relates to a terminal for a rotating armature. Ring main bodies of bus rings (A-C) respectively are connected to U-phase, V-phase and W-phase coils of a stator, and a neutral bus ring (D) connected to common terminals of the respective coils, are arranged in parallel in an axial direction thereof to be resin molded in a resin portion. A connection portion of the bus rings (A-C) welded to the respective U-phase, V-phase and W-phase connection terminals of a coupler, is protruded from the resin portion. Each of the bus rings (A-C) formed as a plate shape in which a ring main body of each bus ring is included in a plane orthogonal to the axial direction. A plate-shaped piece is bent in a direction along the axial direction from one end in a peripheral direction of each of the ring main bodies. The plate-shaped piece of each of the bus rings (A-C) is protruding from the resin portion. A leading end side portion of the plate-shaped piece is formed as a connection portion to each of the connection terminals of the coupler.
- The present invention will be more fully understood from the detailed description given below and from the accompanying drawings which should not be taken to be a limitation on the invention, but are for explanation and understanding only.
- The drawings:
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FIG. 1 is a cross sectional view showing a motor; -
FIGS. 2A and 2B show a stator assembly, iii whichFIG. 2A is a cross sectional view andFIG. 2B is an enlarged view of a main portion; -
FIGS. 3A and 3B show the stator assembly, in whichFIG. 3A is a front elevational view andFIG. 3B is an enlarged view of the main portion; -
FIG. 4A and 4B show a sub assembly in which a terminal is attached to a stator, in whichFIG. 4A is a cross sectional view andFIG. 4B is an enlarged view of a main portion; -
FIGS. 5A and 5B show a core sub assembly, in whichFIG. 5A is a cross sectional view along a line A-A inFIG. 5B , andFIG. 5B is an end elevational view. -
FIGS. 6A to 6D show a terminal, in whichFIG. 6A is a cross sectional view,FIG. 6B is a front elevational view,FIG. 6C is an enlarged view of a main portion ofFIG. 6A , andFIG. 6D is an enlarged view of a main portion ofFIG. 6B ; -
FIGS. 7A to 7C show a bus ring A, in whichFIG. 7A is a front elevational view,FIG. 7B is a cross sectional view along a line B-B inFIG. 7A , andFIG. 7C is a plan view; -
FIGS. 8A to 8C show a bus ring B, in whichFIG. 8A is a front elevational view,FIG. 8B is a cross sectional view along a line B-B inFIG. 8A , andFIG. 8C is a plan view; -
FIGS. 9A and 9B show a bus ring C, in whichFIG. 9A is a front elevational view, andFIG. 9B is a cross sectional view along a line B-B inFIG. 9A ; -
FIGS. 10A and 10B show a bus ring D, in whichFIG. 10A is a front elevational view, andFIG. 10B is a cross sectional view along a line B-B inFIG. 10A ; -
FIGS. 11A and 11B show a coupler, in whichFIG. 11A is a cross sectional view andFIG. 11B is a front elevational view; -
FIGS. 12A and 12B show a metal mold dividing direction of the bus ring and the terminal in accordance with the present invention, in whichFIG. 12A is a perspective view andFIG. 12B is a side elevational view; and -
FIGS. 13A and 13B show a metal mold dividing direction of the bus ring and the terminal in accordance with the prior art, in whichFIG. 13A is a perspective view andFIG. 13B is a side elevational view. - A
DC brushless motor 10 corresponding to a rotating armature in accordance with the present invention is structured, as shown inFIG. 1 , such that anend housing 12 is attached to one end of astator assembly 11, and arotor assembly 13 is rotatably supported to thestator assembly 11 and an inner portion of theend housing 12. - The
stator assembly 11 is structured, as shown inFIGS. 2A to 3B , such that a sub assembly of acylindrical stator 20 and a terminal 30 is stored in an inner periphery of a yoke integrally formed with thehousing 11A and acoupler 40 attached to thehousing 11A is connected to the terminal 30. - The
stator 20 is structured, as shown inFIGS. 4A and 4B , such that a plurality of, for example, four in each of U-phase, V-phase and W-phase (totally twelve)core sub assemblies 20A in the present embodiment, fitted to the inner periphery of thehousing 11A are arranged adjacently on a circumference. Thecore sub assembly 20A is structured by laminating a plurality ofcores 21 constituted by silicon steel plates, attaching aresin bobbin 22 to thelaminated core 21 and winding respective motor coils 23 forming three phases constituted by the U-phase, the V-phase and the W-phase around acoil winding portion 22A of theresin bobbin 22, as shown inFIGS. 5A and 5B . Each of the motor coils 23 is structured such that both ends constituted by a wind starting end and a wind terminating end are respectively set to acoil terminal 23A and acommon terminal 23B, and theseterminals coil winding portion 22A of theresin bobbin 22. Theresin bobbin 22 is provided with aterminal mounting portion 22B (a concave portion) protruding in an axial direction of thehousing 11A along an inner periphery of thehousing 11A, in one end side of thecoil winding portion 22A (FIG. 2B ). - The terminal 30 is attached to the
resin bobbin 22 so as to be positioned in a peripheral direction, an axial direction and a diametrical direction by being embedded in aresin portion 31 formed by the resin mold so as to be integrated, in a state in which respective ringmain bodies 32 of three bus rings A to C and the neutral bus ring D are arranged in parallel in an axial direction, and locking mountinghooks 31A provided at a plurality of positions in an outer periphery of theresin portion 31 to a concave portion of theterminal mounting portion 22B of theresin bobbin 22, as shown inFIGS. 6A to 6D . The ringmain bodies 32 of the bus rings A to C are formed in a C-shaped form so as to be partly cut in the peripheral direction, and the ringmain body 32 of the neutral bus ring D is formed in an annular shape continuously formed in the peripheral direction. - Each of the bus rings A to D is connected to the ring
main body 32 thereof so as to extend to an outer side in the radial direction of the ringmain body 32, and is provided with aterminal portion 33 protruding to an outer portion of theresin portion 31, as shown inFIGS. 7A to 10B . The bus ring A is provided with fourterminal portions 33 to which thecoil terminals 23A of four U-phase motor coils 23 are connected, in the present embodiment. The bus ring B is provided with fourterminal portions 33 to which thecoil terminals 23A of four V-phase motor coils 23 are connected, in the present embodiment. The bus ring C is provided with fourterminal portions 33 to which thecoil terminals 23A of four W-phase motor coils 23 are connected, in the present embodiment. The neutral bus ring D is provided with twelveterminal portions 33 to which thecommon terminals 23B of twelvemotor coils 23 are connected, in the present embodiment. Accordingly, each of the motor coils 23 is star connected by connecting each of theterminal portions 33 connected to the ringmain body 32 of each of the bus rings A to C of the terminal 30 and protruding to an outer side in a radial direction from an outer periphery of theresin portion 31 to thecoil terminal 23A of each of the U-phase, V-phase and W-phase motor coils 23 of thestator 20, and connecting theterminal portion 33 connected to the ringmain body 32 of the neutral bus ring D and protruding from theresin portion 31 to thecommon terminal 23B of each of the motor coils 23. - In each of the bus rings A to D, the
terminal portion 33 is provided with a leading endconcave portion 33B pinched by a leadingend hook portion 33A so as to form a U-shaped outline as shown inFIG. 6D . Theterminals concave portion 33B of theterminal portion 33 of the corresponding bus ring A to D, and are caulked between the leadingend hook portions 33A of theterminal portion 33 so as to be welded to theterminal portion 33. - Each of the bus rings A to C is provided with an external portion connecting
connection portion 34 connected to the ringmain body 32 so as to be bent and stand in a direction along the axial direction of the ringmain body 32 from one end in the peripheral direction of the ringmain body 32, and protruding to an outer side in an axial direction from the side portion of theresin portion 31, as shown inFIGS. 7A to 9B . In the terminal 30, totally threeconnection portions 34 of the bus rings A to C are arranged in parallel to each other (FIG. 6B ). - The
coupler 40 is structured, as shown inFIGS. 11A and 11B , such that U-phase, V-phase and W-phase connection terminals 42 connected to a control circuit in an external portion are embedded in aresin body 41 screwed into the outer surface of thehousing 11A. Each of the U-phase, V-phase and W-phase connection terminals 42 of thecoupler 40 is inserted to an inner portion of thehousing 11A, and is connected to theconnection portion 34 of each of the bus rings A to C of the terminal 30. Each of theconnection terminals 42 is inserted to each of theconnection portions 34 so as to be mated, and welded, as mentioned below. - The
motor 10 has aresolver 50, as shown inFIG. 1 , constituted by aresolver rotor portion 51 and aresolver stator portion 52. In other words, theresolver rotor portion 51 rotating together with therotating shaft 13A is attached to an outer periphery of the rotating shaft 10A of therotor assembly 13. Further, theresolver stator portion 52 is attached to a side of thestator 20, that is, an inner periphery of theend housing 12. Theresolver stator 52 is arranged in such a manner as to surround theresolver rotor portion 51, and detects a rotational position of therotating shaft 13A on the basis of a change of a reluctance generated with respect to theresolver rotor portion 51 caused by the rotation. A predetermined pattern of current is supplied to each of the U-phase, V-phase and W-phase motor coils 23 of thestator 20 via thecoupler 40 and the terminal 30 by the external control circuit in correspondence to the detected rotational position of the rotating shaft 15A, and the drive of themotor 10 is controlled. - Accordingly, in order to improve a bending formability of the bus rings A to C and improve an insert mold formability of the bus ring A to D to the
resin portion 31, at a time of constructing the terminal 30, themotor 10 has the following structures. - In the terminal 30, each of the bus rings A to C is structured, as shown in
FIGS. 12A and 12B (FIG. 12A shows the bus ring A as a representative), such that each of the ringmain bodies 32 is formed in a plate shape included in a plane orthogonal to an axial direction thereof (a direction along a center axis of a circular ring of each of the ring main bodies 32), and has a plate-shapedpiece 35 bent in a straight shape in a direction along an axial direction from one end in a peripheral direction of each of the ringmain bodies 32. Further, the plate-like piece 35 of each of the bus rings A to C is protruded toward all outer side in the axial direction from theresin portion 31, and a leading end side portion of the plate-like piece 35 is formed as aconnection portion 34 to each of theconnection terminals 42 of thecoupler 40. - In
FIG. 12B , reference symbol P denotes a dividing direction of the metal mold at a the of forming theresin portion 31 of the terminal 30 by insert molding the bus rings A to D. - In accordance with the present embodiment, the following operations and effects are achieved.
- In the terminal 30, the plate-shaped
piece 35 forming theconnection portion 34 of thecoupler 40 to each of theconnection terminals 42 and protruding from theresin portion 31 in each of the bus rings A to C is bent in a direction along the axial direction from the ringmain body 32 of each of the bus rings A to C. - Accordingly, it is easy to execute the bending work of the bus rings A to C, and it is possible to improve the bending formability. Further, since the plate-shaped
piece 35 forming theconnection portion 34 of the bus rings A to C extends in parallel in the dividing direction P thereof at a time of insert molding, by inserting each of the bus rings A to D into the metal mold so as to form theresin portion 31, and intending to divide the metal mold along the axial direction, it is not necessary to arrange the slide metal mold orthogonal to the dividing direction P, and the insert molding formability of the bus rings A to D is good. - Further, in order to prevent the
resin portion 31 of the terminal 30 from melting due to the heat generation at a time of welding each of theconnection terminals 42 of thecoupler 40 to theconnection portions 34 of a plurality of bus rings A to C resin molded so as to construct the terminal 30, themotor 10 has the following structures. - In the terminal 30, each of the bus rings A to C is provided with a
heat radiation portion 36 positioned in an outer side of theresin portion 31 so as to be exposed, between the ringmain body 32 molded to theresin portion 31 and theconnection portion 34, as shown inFIGS. 2A to 4B . At this time, each of the bus rings A to C has a plate-shapedpiece 35 formed by the ringmain body 32 in a C-shaped form, bent in a direction along the axial direction of the ringmain body 32 from one end in the peripheral direction of each of the ringmain bodies 32 so as to stand up, and protruding toward an outer side in the axial direction from theresin portion 31. In the terminal 30, a root side portion with respect to theresin portion 31 of the plate-shapedpiece 35 in the plate-shapedpiece 35 of each of the bus rings A to C is formed as theheat radiation portion 36 extending in a radial direction of the ringmain body 32 so as to be formed long. Further, a leading end side portion of the plate-shapedpiece 35, a small piece portion in a leading end lower side protruding from a center side end in the radial direction of the ringmain body 32 in the plate-shapedpiece 35 toward the outer side in the axial direction of the ringmain body 32 is formed as a weld connection portion 134. In this case, the terminal 30 is provided with apositioning portion 37 mentioned below for theconnection terminal 42 of thecoupler 40, in a leading end upper side of the plate-shapedpiece 35. - Accordingly, each of the
connection terminals 42 of thecoupler 40 is mated with theconnection portion 34 protruding to the outer side in the axial direction from theresin portion 31 via theheat radiation portion 36, in each of the bus rings A to C of the terminal 30, and is welded, as shown inFIGS. 2A to 3B . - In accordance with the present embodiment, the following operations and effects can be achieved.
- (a) Each of the bus rings A to C of the terminal 30 is provided with the
heat radiation portion 36 positioned in the outer side of theresin portion 31, between the ringmain body 32 and theconnection portion 34. Accordingly, the heat generated at a time of welding each of theconnection terminals 42 of thecoupler 40 to theconnection portion 34 of each of the bus rings A to C is air cooled and radiated by theheat radiation portion 36 positioned in the outer side of theresin portion 31, before being transmitted to the ringmain body 32, and is not directly accumulated in theresin portion 31, whereby it is possible to easily prevent theresin portion 31 from melting and being dispersed. - (b) Each of the bus rings A to C of the terminal 30 has the plate-shaped
piece 35 connected to the ringmain body 32, and protruding in the axial direction from theresin portion 31, the root portion with respect to theresin portion 31 of the plate-shapedpiece 35 is formed as theheat radiation portion 36, and the leading end side portion of the plate-shapedpiece 35 is formed as theweld connection portion 34. Accordingly, theheat radiation portion 36 positioned in the outer side of theresin portion 31 is set to a plate-shaped area having a great surface area, and it is possible to easily secure the required heat radiating performance. - Next, in order to easily mate each of the
connection terminals 42 of thecoupler 40 to theconnection portion 34 in each of the bus rings A to C of the terminal 30 at the connected position thereof, and intend to stabilize the welding between the both, themotor 10 has the following structures. - In the terminal 30, each of the bus rings A to C is provided with a
positioning portion 37 positioning and guiding each of theconnection terminals 42 of thecoupler 40 to a predetermined connection position to theconnection portion 34, in theconnection portion 34 thereof as shown inFIGS. 2A to 4B . At this time, each of the bus rings A to C has a plate-shapedpiece 35 protruding in the axial direction and forming theconnection portion 34 as mentioned above shown inFIGS. 6A to 9B , is provided with thepositioning portion 37 near a side of the portion forming theconnection portion 34 of the plate-shapedpiece 35, that is, ear an upper side with respect to theconnection portion 34 via anair gap portion 38, and is provided with a taper-shapedopen positioning groove 37A in an upper side (an end surface facing to the coupler 40) of thepositioning portion 37. Theconnection portion 34 and thepositioning portion 37 are flush with theheat radiation portion 36 mentioned above. On the other hand, each of theconnection terminals 42 of thecoupler 40 is formed as a band-plate shaped plate-shapedpiece 43 as shown inFIGS. 11A and 11B , and aslit 43B having a fixed length is formed in a bifurcated leadingend fork portion 43A formed in a side of the leading end portion of the plate-shapedpiece 43. - Accordingly, each of the
connection terminals 42 is positioned in three mutually orthogonal directions comprising an axial direction, an axial perpendicular direction and a radial direction of the terminal 30 by fitting theslit 43B of the leadingend fork portion 43A in each of theconnection terminals 42 of thecoupler 40 to a groove bottom portion of thepositioning groove 37A provided in the plate-shapedpiece 35 in each of the bus rings A to C of the terminal 30. As a result, each of theconnection terminals 42 is precisely positioned to a predetermined connection position of theconnection portion 34 of each of the bus rings A to C. In the present embodiment, the leadingend fork portion 43A of the plate-shapedpiece 43 in each of theconnection terminals 42 of thecoupler 40 forms the air gap portion 38 (serving as the air cooling heat radiation portion of theconnection portion 34 to which the leadingend fork portion 43A of theconnection terminal 42 is welded) among the plate-shapedportion 35 of thepositioning portion 37 in each of the bus rings A to C, the positioningportion 37 and theconnection portion 34, as shown inFIGS. 2A to 3B , and further pinches the plate-shapedpiece 35 of theconnection portion 34, and the leadingend fork portion 43A of the plate-shapedpiece 43 in each of theconnection terminals 42 is welded to the plate-shapedpiece 35 of theconnection portion 34 in each of the bus rings A to C. - In accordance with the present embodiment, the following operations and effects can be achieved.
- (a) The
positioning portion 37 provided in theconnection portion 34 of each of the bus rings A to C positions and guides each of theconnection terminals 42 of thecoupler 40 to the predetermined connection position between theconnection portions 34 of each of the bus rings A to C. Accordingly, it is possible to easily mate the weld portion between each of theconnection terminals 42 of thecoupler 40 and each of the bus rings to the connection position thereof so as to intend to stabilize the welding between the both, and it is possible to improve an assembling workability and a welding characteristic between the both. - (b) The
slit 43B formed in the leading end portion of the plate-shapedconnection terminal 42 of thecoupler 40 is fitted to the plate-shapedconnection portion 34 of each of the bus rings A to C, and the groove bottom portion of thepositioning groove 37A provided in the plate-shapedconnection portion 34. Theconnection terminal 42 of thecoupler 40 is derived and guided to thepositioning groove 37A provided in theconnection portion 34 of each of the bus rings A to C so as to be smoothly positioned at the connection position to theconnection portion 34. - As heretofore explained, embodiments of the present invention have been described in detail with reference to the drawings. However, the specific configurations of the present invention are not limited to the illustrated embodiments but those having a modification of the design within the range of the presently claimed invention are also included in the present invention.
- Although the invention has been illustrated and described with respect to several exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made to the present invention without departing from the spirit and scope thereof. Therefore, the present invention should not be understood as limited to the specific embodiment set out above, but should be understood to include all possible embodiments which can be encompassed within a scope of equivalents thereof with respect to the features set out in the appended claims.
Claims (16)
1. A terminal for a rotating armature comprising:
ring main bodies of bus rings (A-C) respectively connected to U-phase, V-phase and W-phase coils of a stator, and a neutral bus ring (D) connected to common terminals of the respective coils, being arranged in parallel in an axial direction thereof to be resin molded in a resin portion,
a connection portion of the bus rings (A-C) welded to the respective U-phase, V-phase and W-phase connection terminals of a coupler, being protruded from the resin portion,
each of the bus rings (A-C) formed as a plate shape in which a ring main body of each bus ring is included in a plane orthogonal to the axial direction,
a plate-shaped piece bent in a direction along the axial direction from one end in a peripheral direction of each of the ring main bodies, and
the plate-shaped piece of each of the bus rings (A-C) protruding from the resin portion, and
a leading end side portion of the plate-shaped piece being formed as a connection portion to each of the connection terminals of the coupler.
2. A terminal for a rotating armature as claimed in claim 1 , wherein in the plate-shaped piece of each of the bus rings (A-C), a root side portion with respect to the resin portion of the plate-shaped piece is formed as a heat radiation portion.
3. A terminal for a rotating armature as claimed in claim 1 , wherein in the leading end side portion of each of the bus rings (A-C) a leading end lower portion positioned close to a center in a radial direction of each of the ring main bodies is formed as a connection portion to each of the connection terminals of the coupler, and a leading end upper portion positioned close to an outer side in the radial direction of each of the ring main bodies is formed as a positioning portion for each of the connection terminals of the coupler.
4. A terminal for a rotating armature as claimed in claim 2 , wherein in the leading end side portion of each of the bus rings (A-C), a leading end lower portion positioned close to a center in a radial direction of each of the ring main bodies is formed as a connection portion to each of the connection terminals of the coupler, and a leading end upper portion positioned close to an outer side in the radial direction of each of the ring main bodies is formed as a positioning portion for each of the connection terminals of the coupler.
5. A terminal for a rotating armature as claimed in claim 1 , wherein the plate-shaped piece is formed by being folded in a straight shape in a direction along the axial direction from one end in a peripheral direction of each of the ring main bodies, and the plate-shaped piece protrudes toward an outer side in the axial direction from the resin portion.
6. A terminal for a rotating armature as claimed in claim 2 , wherein the heat radiation portion is positioned in an outer side of the resin portion and is exposed to the outer side of the resin portion, between the ring main body molded to resin portion and the connection portion.
7. A terminal for a rotating armature as claimed in claim 3 , wherein a positioning groove open in a taper shape is provided in an end surface facing to the coupler corresponding to an upper side of the positioning portion.
8. A terminal for a rotating armature as claimed in claim 4 , wherein a positioning groove open in a taper shape is provided in an end surface facing to the coupler corresponding to an upper side of the positioning portion.
9. A terminal for a rotating armature as claimed in claim 3 , wherein the connection portion and the positioning portion are flush with the heat radiation portion.
10. A terminal for a rotating armature as claimed in claim 4 , wherein the connection portion and the positioning portion are flush with the heat radiation portion.
11. A terminal for a rotating armature as claimed in claim 7 , wherein the connection portion and the positioning portion are flush with the heat radiation portion.
12. A terminal for a rotating armature as claimed in claim 8 , wherein the connection portion and the positioning portion are flush with the heat radiation portion.
13. A terminal for a rotating armature as claimed in claim 3 , wherein each of the connection terminals of the coupler is formed as a band-plate shaped plate-shaped piece, and is structured such that a slit having, a fixed length is formed in a bifurcated leading end fork portion formed in the leading end portion side of the plate-shaped piece.
14. A terminal for a rotating armature as claimed in claim 5 , wherein each of the connection terminals of the coupler is formed as a band-plate shaped plate-shaped piece, and is structured such that a slit having a fixed length is formed in a bifurcated leading end fork portion formed in the leading end portion side of the plate-shaped piece.
15. A terminal for a rotating armature as claimed in claim 7 , wherein each of the connection terminals of the coupler is formed as a band-plate shaped plate-shaped piece, and is structured such that a slit having a fixed length is formed in a bifurcated leading end fork portion formed in the leading end portion side of the plate-shaped piece.
16. A terminal for a rotating armature as claimed in claim 8 , wherein each of the connection terminals of the coupler is formed as a band-plate shaped plate-shaped piece, and is structured such that a slit having a fixed length is formed in a bifurcated leading end fork portion formed in the leading end portion side of the plate-shaped piece.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2006199912A JP2008029138A (en) | 2006-07-21 | 2006-07-21 | Terminal for rotating electric machine |
JP2006-199912 | 2006-07-21 |
Publications (2)
Publication Number | Publication Date |
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US20080018193A1 true US20080018193A1 (en) | 2008-01-24 |
US7374462B2 US7374462B2 (en) | 2008-05-20 |
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US11/685,743 Expired - Fee Related US7374462B2 (en) | 2006-07-21 | 2007-03-13 | Terminal for rotating armature |
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US (1) | US7374462B2 (en) |
EP (1) | EP1881584B1 (en) |
JP (1) | JP2008029138A (en) |
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US20150145359A1 (en) * | 2013-11-27 | 2015-05-28 | Tyco Electronics Japan G. K. | Connector For Motor and Connector Assembly For Motor |
EP2963778A3 (en) * | 2014-07-01 | 2016-07-27 | Toyota Jidosha Kabushiki Kaisha | Stator for a rotary electric machine |
CN105322682A (en) * | 2014-07-01 | 2016-02-10 | 丰田自动车株式会社 | Stator for rotary electric machine |
US9806577B2 (en) | 2014-07-01 | 2017-10-31 | Toyota Jidosha Kabushiki Kaisha | Stator with neutral line secured to stator yoke |
CN114026770A (en) * | 2019-06-28 | 2022-02-08 | 日本电产株式会社 | Bus and motor |
DE102019210126A1 (en) * | 2019-07-09 | 2021-01-14 | Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Würzburg | Stator for an electric machine |
DE102021102761B3 (en) | 2021-02-05 | 2022-08-04 | Nidec Motors & Actuators (Germany) Gmbh | Brushless electric motor with busbar unit |
Also Published As
Publication number | Publication date |
---|---|
EP1881584A3 (en) | 2011-04-27 |
EP1881584A2 (en) | 2008-01-23 |
EP1881584B1 (en) | 2012-09-05 |
US7374462B2 (en) | 2008-05-20 |
JP2008029138A (en) | 2008-02-07 |
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